Abstract: In some aspects, methods of disengaging a plasma control circuit within a plasma arc torch of a plasma processing system to place the torch into a safety-locked mode can include providing: a plasma control circuit configured to convey a current from the plasma cutting system through the plasma arc torch to one or more consumables disposed in the torch and an operator interface switch connected to the plasma control circuit and configured to initiate generation of a plasma arc from the plasma arc torch; and activating a switch, separate from the operator interface switch, disposed on the torch and connected to the plasma control circuit to disconnect the plasma control circuit to limit the current, including pilot current, from flowing to the one or more consumables.

Abstract: A connector component configured for coupling a consumable component to a plasma arc torch is provided. The connector component comprises a body having a proximal end and a distal end disposed along and defining a longitudinal axis. The connector component includes at least two engagement regions disposed radially about the longitudinal axis on a surface of the body. Each engagement region includes at least one engagement feature disposed on the surface of the body. The connector component also includes at least two free regions disposed radially about the longitudinal axis on the surface of the body. Each free region is radially located between a pair of the engagement regions and characterized by an absence of the engagement feature.

Abstract: A method for synthesizing (R)-(?)-1-((S)-2-diphosphino ferrocene)-ethyl-diphosphine by: 1) adding vinylferrocene, a chiral catalyst, and toluene to a first drying reactor; adding a phosphorus-hydrogen compound to the first drying reactor and allowing reactants in the first drying reactor to react; cooling the first drying reactor; adding water dropwise to the first drying reactor; extracting, drying, and recrystallizing a product to yield (R)-1-ferrocenylethyl-diphosphine; 2) adding the (R)-1-ferrocenylethyl-diphosphine and ether to a second drying reactor; adding a hexane solution including diethylzinc to the second drying reactor and allowing reactants in the second drying reactor to react; adding a phosphorus-chlorine compound dropwise to the second drying reactor, and heating and refluxing the reaction mixture in the second drying reactor; adding water to quench the reaction mixture in the second drying reactor; and extracting, drying, and recrystallizing the reaction mixture.

Abstract: A plasma cutting system is provided. The system includes a power source configured to generate a plasma arc, and a plasma arc torch connected to the power source for delivering the plasma arc to a workpiece. The plasma arc torch defines a multi-function fluid flow path for sustaining the plasma arc and cooling the plasma arc torch such that the plasma cutting system has a power-to-gas flow ratio of at least 2 kilowatts per cubic feet per minute (KW/cfm). The power-to-gas flow ratio comprises a ratio of power of the generated plasma arc to a total gas flow supplied to the plasma arc torch.

Abstract: In some aspects, methods for controlling a plasma arc in a plasma torch of a plasma cutting system in a low operating current mode can include: receiving, by a computing device within the plasma power supply, a command to begin a plasma processing operation; generating a pilot arc command to generate a pilot arc within the plasma torch, the generating of the pilot arc command including directing an electrical signal and a gas flow to the plasma torch, the electrical signal being configured to generate the pilot arc at a current having a first arc amperage magnitude; and generating an operational arc command to facilitate a transition from the pilot arc to an operational plasma arc, the generating of the operational arc command including adjusting the current directed to the plasma torch to be a second arc amperage magnitude that is lower than the first arc amperage magnitude.

Abstract: A method for synthesizing (R)-(?)-1-((S)-2-diphosphino ferrocene)-ethyl-diphosphine by: 1) adding vinylferrocene, a chiral catalyst, and toluene to a first drying reactor; adding a phosphorus-hydrogen compound to the first drying reactor and allowing reactants in the first drying reactor to react; cooling the first drying reactor; adding water dropwise to the first drying reactor; extracting, drying, and recrystallizing a product to yield (R)-1-ferrocenylethyl-diphosphine; 2) adding the (R)-1-ferrocenylethyl-diphosphine and ether to a second drying reactor; adding a hexane solution including diethylzinc to the second drying reactor and allowing reactants in the second drying reactor to react; adding a phosphorus-chlorine compound dropwise to the second drying reactor, and heating and refluxing the reaction mixture in the second drying reactor; adding water to quench the reaction mixture in the second drying reactor; and extracting, drying, and recrystallizing the reaction mixture.

Abstract: A component for a contact start plasma arc torch is provided. The component includes a hollow body defining a channel with a longitudinal axis. The channel is capable of slideably receiving an electrode body along the longitudinal axis. The component includes a contact element disposed in the hollow body and includes a first surface and a second surface. The first surface is adapted to facilitate electrical communication with a power supply and the second surface is adapted to physically contact a surface of the electrode body when the plasma arc torch is operated in a transferred arc mode. In addition, the second surface is characterized by the absence of physical contact with the surface of the electrode body when the torch is operated in a pilot arc mode.

Abstract: An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.

Abstract: A torch tip for a plasma arc torch includes a body having a first end, configured to attach to the torch, and a second end, where an end wall is disposed. A plasma exit orifice is formed in the end wall. At least two castellations are formed in the end wall. Each castellation has a castellation width defined by the distance between the sidewalls of that castellation. At least one slot is disposed between two castellations. Each slot has a slot width defined by a distance between the sidewalls of its adjacent castellations. The slot width can be at least twice the castellation width. Each slot also has a slot floor and an exterior shape. The slot floor can have slope that tapers toward the first end of the body in an outward radial direction and the exterior shape of the slot can have a generally V-shaped or U-shaped contour.

Abstract: A crown for a plasma arc torch is provided. The crown includes a body defining a proximal and a distal end. The body includes an electrically conductive material. The crown also includes at least one raised feature at the proximal end of the body. The raised feature is adapted to activate a consumable sensor inside of the plasma arc torch. The crown further includes a biasing surface at the proximal end of the body for physically contacting a resilient element.

Abstract: A consumable cartridge for a plasma arc torch is provided. The consumable cartridge includes an outer component defining a substantially hollow body, an inner component disposed substantially within the hollow body of the outer component, and a hollow region between the rear portion of the inner component and the outer component. The inner component includes a forward portion configured to axially secure and rotatatably engage the outer component to the inner component and a rear portion substantially suspended within the hollow body of the outer component. The rear portion is axially secured and rotatably engaged with the outer component via the forward portion. The hollow region is configured to receive a torch head to enable mating between the rear portion of the inner component and a cathode of the torch head.

Abstract: In some aspects, nozzles for gas-cooled plasma torches can include a body having a first end and a second end that define a longitudinal axis; a plenum region substantially formed within the body that extends from the first end and is configured to receive a plasma gas flow; an exit orifice located at the second end oriented substantially coaxially with the longitudinal axis, the exit orifice fluidly connected to the plenum region; and a feature on an outer surface of the body to increase cooling by receiving a high velocity cooling gas flow flowing in a direction along a length of the body, an impingement surface of the feature to receive the cooling gas flow at a substantially perpendicular direction relative to the impingement surface and to redirect the cooling gas flow to promote cooling and uniform shield flow.

Abstract: A method for measuring a temperature of magnetic junction switchable using spin transfer. The magnetic junction includes at least one magnetic layer. The method includes measuring a temperature variation of at least one magnetic characteristic for the magnetic layer(s) versus temperature. The method also includes measuring a bias variation in the magnetic characteristic versus an electrical bias for the magnetic junction. This measurement is performed such that spin transfer torque-induced variation(s) in the magnetic characteristic(s) are accounted for. The temperature versus the electrical bias for the magnetic junction is determined based on the temperature variation and the bias variation.

Abstract: A cartridge for an air-cooled plasma arc torch is provided. The cartridge includes a swirl ring having a molded thermoplastic elongated body with a distal end, a proximal end, and a hollow portion configured to receive an electrode. The swirl ring also has a plurality of gas flow openings defined by the distal end of the elongated body and configured to impart a swirling motion to a plasma gas flow for the plasma arc torch. The swirl ring further includes a nozzle retention feature on a surface of the elongated body at the distal end for retaining a nozzle to the elongated body. The cartridge further includes a cap affixed to the proximal end of the elongated body of the swirl ring for substantially closing the proximal end of the elongated body.

Abstract: A plasma cutting system is provided. The system includes a power source configured to generate a plasma arc, and a plasma arc torch connected to the power source for delivering the plasma arc to a workpiece. The plasma arc torch defines a multi-function fluid flow path for sustaining the plasma arc and cooling the plasma arc torch such that the plasma cutting system has a power-to-gas flow ratio of at least 2 kilowatts per cubic feet per minute (KW/cfm). The power-to-gas flow ratio comprises a ratio of power of the generated plasma arc to a total gas flow supplied to the plasma arc torch.

Abstract: In some aspects, nozzles for a gas-cooled plasma torches can include a hollow generally cylindrical body having a first end and a second end that define a longitudinal axis, the second end of the body defining a nozzle exit orifice; a gas channel formed in the first end between an interior wall and an exterior wall of the cylindrical body, the gas channel directing a gas flow circumferentially about at least a portion of the body; an inlet passage formed substantially through a radial surface of the exterior wall and fluidly connected to the gas channel; and an outlet passage at least substantially aligned with the longitudinal axis and fluidly connected to the gas channel.

Abstract: In some aspects, methods for providing a uniform shield gas flow for an air-cooled plasma arc torch can include supplying a shield gas to a shield gas flow channel defined by an exterior surface of a nozzle and an interior surface of a shield; flowing the shield gas along the shield gas flow channel; reversing the flow of the shield gas along the shield gas flow channel using a recombination region, the recombination region comprising at least one flow reversing member; and flowing the shield gas from the mixing region to an exit orifice of the shield, thereby producing a substantially uniform shield gas flow at the exit orifice.

Abstract: In some aspects, nozzles for gas-cooled plasma torches can include a body having a first end and a second end that define a longitudinal axis; a plenum region substantially formed within the body that extends from the first end and is configured to receive a plasma gas flow; an exit orifice located at the second end oriented substantially coaxially with the longitudinal axis, the exit orifice fluidly connected to the plenum region; and a feature on an outer surface of the body to increase cooling by receiving a high velocity cooling gas flow flowing in a direction along a length of the body, an impingement surface of the feature to receive the cooling gas flow at a substantially perpendicular direction relative to the impingement surface and to redirect the cooling gas flow to promote cooling and uniform shield flow.

Abstract: In some aspects, nozzles for a gas-cooled plasma torches can include a hollow generally cylindrical body having a first end and a second end that define a longitudinal axis, the second end of the body defining a nozzle exit orifice; a gas channel formed in the first end between an interior wall and an exterior wall of the cylindrical body, the gas channel directing a gas flow circumferentially about at least a portion of the body; an inlet passage formed substantially through a radial surface of the exterior wall and fluidly connected to the gas channel; and an outlet passage at least substantially aligned with the longitudinal axis and fluidly connected to the gas channel.

Abstract: An electrode for a plasma arc torch includes a generally cylindrical elongated body formed of an electrically conductive material. The elongated body includes a proximal end that connects to a power supply and a distal end that receives an emissive element. The electrode can include a flange that is disposed about a surface relative to the distal end of the elongated body, extends radially from the surface of the elongated body, and is utilized to establish a uniform gas flow distribution of a plasma gas flow about the distal end of the elongated body. The electrode can include a contact element that is in electrical communication with the proximal end of the electrode. The contact element includes seating portion that has an outer width that is greater than the outermost diameter of the electrode body and is configured to position the contact element within the plasma arc torch.